Apparatuses, methods and systems for reinforcing concrete panels using spiral reinforcing bars

ABSTRACT

Reinforced concrete panels that are reinforced by spiral metal bars. In a reinforced concrete panel having a longitudinal axis and a transverse axis, where the longitudinal axis defines the length of the concrete panel, the spiral metal bars are located parallel to the longitudinal axis. The spiral metal bars are parallel to each other, such that the bars do not touch each other. Additionally, the bars are perpendicular to the transverse axis. During formation of the reinforced concrete panel, the bars are lowered into a mold to which concrete mix is added. The bars are lowered by a hanger assembly that releasably secures the spiral metal bars and maintains their parallel relationship. After the viscosity of the mix is sufficiently reduced, the hanger assembly releases the bars into the concrete mix, and is removed from the mold. The reinforced concrete panel is then removed from the mold, and cut as necessary to make smaller individual reinforced concrete panels.

FIELD OF THE INVENTION

[0001] The present invention relates generally to the reinforcement of concrete panels, and more particularly, to apparatuses, methods and systems for reinforcing autoclaved aerated concrete panels.

BACKGROUND OF THE INVENTION

[0002] In order to manufacture aerated concrete products, an aerated concrete composition that includes the finely ground components of sand, lime, cement, a sulfate component and water is typically mixed and then poured into a mold, whereby the aerated concrete composition is made to form a foam via suitable agents. The foam may be formed by dispersing aluminum powder into the concrete mixture, which reacts with the OH.sup. ions produced by the reaction of quicklime with water, thereby liberating hydrogen from the mixture. The liberated hydrogen allows the aerated concrete mixture to swell—a process referred to as foaming and setting.

[0003] After the aerated concrete composition sets, the aerated concrete cake is removed from the mold and cut into desired panels for the final product. The cut aerated concrete cakes are then subjected to steam hardening in an autoclave. After steam hardening, the finished aerated concrete panels may be packed and delivered to the end user.

[0004] Although concrete panels may be formed without being reinforced, concrete panels which are reinforced are often desirable in applications requiring panels that may be subjected to high loads and stresses. Therefore, one critical component in the manufacture of autoclaved aerated concrete products is reinforcement of concrete cakes and panels during production and use.

[0005] It is known in the art to reinforce aerated concrete panels by using a reinforcing cage made up of at least two spaced reinforcing mats and transversely extending cross-rods, the latter being welded at their cross-points to the main, longitudinally extending rods. The mats making up the cage are spaced apart by various types of connector bars which are welded to the bars of the mats. The connector bars are provided with openings for the passage of lift rods.

[0006] West German Utility Model No. 78 19 077 is one example of a reinforcing cage having mats which are spaced apart with plate strips which are welded to the cross bars. These plate strips, which are substantially U-shaped in side elevation, have in the free terminal area of their U-legs stops or connecting openings with which they are positioned on a crossbar and a main bar so that the base of the U-shape faces towards the interior of the space between reinforcing mats with the legs welded to the crossbars. In another arrangement, illustrated in U.S. Pat. No. 4,667,452, two mats making up a cage are spaced apart from each other by connector bars which are bent into a C-shape from weldable steel bars, each connector bar having a pair of opposed legs and a spacer portion connecting those legs.

[0007] Each of the aforementioned arrangements require both longitudinally extending rods and transverse rods welded or otherwise connected thereto to create the reinforcing mats, and thereby, the reinforcing cages. The longitudinally extending rods of the reinforcing cage provide the flexural tensile resistance for the panels. The transverse rods connected to the longitudinal rods provide tensile anchorage for the longitudinal rods, because the rods are smooth and cannot develop any appreciable bond stress within the panels along their lengths to appropriately strengthen the panels.

[0008] The presence of both longitudinally extending rods and transverse rods increases the expense of the reinforcing cage and the concrete panels due to the amount of cutting, reinforcing and welding of the rods that is required to produce the reinforcing cage. Their presence also limits flexibility in cutting the panels to the desired lengths and widths. In particular, after production, many reinforced panels must be dry-cut to certain lengths and widths specific to a certain project. Because of the presence of the longitudinally extending rods and the transverse rods, extreme care must be taken to ensure that an adequate number of transverse anchor bars remain after the dry-cutting to safely meet the tensile anchorage requirements of the longitudinal reinforcement. Furthermore, the requirement of C-shaped connector bars increases the cost, time and materials required to construct a reinforced concrete panel.

[0009] Consequently, there is a need for an apparatus and method for inexpensively and efficiently reinforcing autoclaved aerated concrete panels to minimize the product costs associated with cutting, reinforcing and welding the elements used to create the reinforcing cage for the panels. Such an apparatus and method would preferably also provide more flexibility in cutting such concrete panels to project specific lengths and widths.

SUMMARY OF THE INVENTION

[0010] Apparatuses, methods and systems of the present invention provide reinforced concrete panels that are reinforced by spiral metal bars, rather than by metal cages, as in the prior art. In a reinforced concrete panel having a longitudinal axis and a transverse axis, wherein the longitudinal axis defines the length of the panel, the spiral metal bars are located parallel to the longitudinal axis. The spiral metal bars are also parallel to each other throughout the length of a concrete panel and are perpendicular to the transverse axis of the concrete panel. The spiral structure of the bars provides adhesion between the bars and adjacent concrete, thereby obviating the need for transverse bars and eliminating the need for mats or cages to reinforce a concrete panel. During formation of the reinforced concrete panel, the bars are lowered into a concrete mix or slurry by a hanger assembly that releasably secures the spiral metal bars while maintaining the parallel relationship of the bars. After the viscosity of the mix is sufficiently reduced, the hanger assembly releases the bars and is removed from the mix.

[0011] According to one embodiment of the present invention, there is disclosed a reinforced concrete panel, wherein the reinforced concrete panel includes at least one spiral metal bar therein for reinforcing the reinforced concrete panel.

[0012] According to one aspect of the invention, the reinforced concrete panel is an autoclaved aerated concrete panel. According to another aspect of the present invention, the at least one spiral metal bar is constructed of a material selected from the group consisting of steel, aluminum, carbon, steel alloy, aluminum alloy, stainless steel, and steel alloy. According to yet another aspect of the invention, the reinforced concrete panel includes a longitudinal axis and a transverse axis, and the at least one spiral metal bar is oriented lengthwise in the direction of the longitudinal axis. Additionally, where the longitudinal axis defines the length of the concrete panel, the at least one spiral metal bar can run substantially the entire length of the reinforced concrete panel. Additionally, the at least one spiral metal bar can include a plurality of spiral metal bars, where each one of the plurality of spiral metal bars is parallel to each other one of the plurality of spiral metal bars.

[0013] According to another embodiment of the present invention, there is disclosed a method for constructing a reinforced concrete panel using at least one spiral metal bar. The method includes inserting the at least one spiral metal bar into a mold that is to receive a concrete mix, pouring a concrete mix into the mold, wherein the mold defines the shape of the concrete mix during a reduction of the viscosity of the concrete mix, and removing the mold after the concrete mix can retain the shape of the mold without the mold, to produce a reinforced concrete panel.

[0014] According to one aspect of the present invention, inserting the at least one spiral metal bar into the mold includes inserting a plurality of spiral metal bars into the mold, wherein each one of the plurality of spiral metal bars is parallel to each other one of the plurality of spiral metal bars. According to another aspect of the present invention, the method further includes cutting the reinforced concrete panel after the reinforced concrete panel has been removed from the mold, to produce a plurality of smaller reinforced concrete panels. The method can also include curing the reinforced concrete panel.

[0015] According to yet another aspect of the present invention, inserting the at least one spiral metal bar into the mold includes releasably mounting the at least one spiral metal bar to a hanger assembly, and lowering said hanger assembly into the mold. Furthermore, the method can include releasing the at least one spiral metal bar from the hanger assembly after pouring the concrete mix into the mold and prior to removing the mold. Releasing the at least one spiral metal bar from the hanger assembly can also include rotating the hanger assembly to release the at least one spiral metal bar.

[0016] According to yet another embodiment of the present invention, there is disclosed a system for constructing reinforced concrete panels. The system includes a mold for receiving concrete mix, and for maintaining the shape of the concrete mix during the reduction in viscosity of the concrete mix, and a hanger assembly for releasably securing in a parallel orientation a plurality of spiral metal bars, wherein the hanger assembly is lowered into the mold, and wherein the hanger assembly is removed from the concrete mix after releasing the plurality of spiral metal bars into the concrete mix after the viscosity of the concrete mix is sufficient to retain the position of the spiral metal bars in the concrete mix.

[0017] According to one aspect of the present invention, the system further includes a bridge located substantially above the mold, and wherein the hanger assembly is supported by the bridge. According to another aspect of the present invention, the system further includes a needle connecting the hanger assembly and the bridge, wherein the needle is rotatable with respect to the bridge to facilitate the release of the plurality of spiral metal bars from the hanger assembly. Finally, according to yet another aspect of the invention, the hanger assembly can include a plurality of clips for releasably securing the plurality of spiral metal bars to the hanger assembly.

[0018] According to yet another embodiment of the present invention, there is disclosed a reinforced concrete panel including at least one shaped reinforcement bar therein for reinforcement.

[0019] According to one aspect of the invention, the reinforced concrete panel is an autoclaved aerated concrete panel. According to another aspect of the invention, the at least one shaped reinforcement bar is constructed of a metal selected from the group consisting of steel, aluminum, carbon, steel alloy, aluminum alloy, stainless steel, and a steel alloy.

[0020] According to yet another aspect of the invention, the reinforced concrete panel can include a longitudinal axis and a transverse axis, and the at least one shaped reinforcement bar is oriented lengthwise in the direction of the longitudinal axis. Furthermore, the at least one shaped reinforcement bar can include a plurality of shaped reinforcement bars, wherein each one of the plurality of shaped reinforcement bars is parallel to each other one of the plurality of shaped reinforcement bars. Additionally, the reinforced concrete panel can include a longitudinal axis and a transverse axis, where the longitudinal axis defines the length of the concrete panel, and where the at least one shaped reinforcement bar runs substantially the entire length of the reinforced concrete panel.

[0021] It will be appreciated that the present invention provides a simple method for the construction of reinforcement of concrete panels, such as autoclaved aerated concrete panels. Because parallel spiral metal rods are used in place of steel cages, which require transverse rods and C-shaped connector bars, the cost of construction of the concrete panels is reduced because less material is needed to reinforce the concrete panels. Likewise, eliminating the requirement for steel cages reduces the manpower and/or machinery needed to form the reinforced concrete panels. The spiral metal rods also enable the concrete panels to be cut more easily than conventional panels having cages, as less steel is utilized in a comparably sized cage, and because transverse metal bars are eliminated. Furthermore, because the spiral bars adhere to adjacent concrete along the entire length of each bar, and because no transverse bars are needed to facilitate adhesion between concrete and bars oriented longitudinally within the panel, the concrete panel may be cut along a transverse axis without compromising the integrity of the reinforcement, unlike in the prior art.

[0022] Although these are a few of the advantages of the present invention, additional advantages will be readily apparent to those skilled in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

[0023]FIG. 1 shows the process of constructing concrete panels having metal reinforcing cages therein, in accordance with one aspect of the prior art.

[0024]FIG. 2 shows a perspective view of a reinforcement cage located within a concrete panel, in accordance with one aspect of the prior art.

[0025]FIG. 3 shows a spiral section of reinforcing metal for use in reinforcing concrete panels, according to one aspect of the present invention.

[0026]FIG. 4A shows a perspective view of a concrete panel having spiral reinforcing bars therein, according to one aspect of the present invention.

[0027]FIG. 4B shows an end view of a concrete panel having spiral reinforcing bars therein, according to one aspect of the present invention.

[0028]FIG. 5 shows a hanger assembly for inserting spiral reinforcing bars into concrete, according to one aspect of the present invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

[0029] The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.

[0030] Referring now to FIG. 1, there is shown a process 1 of constructing concrete panels having metal reinforcing cages therein, in accordance with one aspect of the prior art. In this process 1, a length of wire, typically located on a spool 10, is straightened and cut 12 into predefined lengths such that the wire can be used to form a metal cage used in reinforce a concrete panel. Typically, the wire is steel, and ranges in diameter from about 4 mm to about 12 mm. After the wire is cut into predefined lengths to form bars, the bars are bundled 14 and placed into a mat welder 16, which arranges the bars into a grid configuration and welds the bars together at multiple intersection points so that a grid of bars, or a mat 18, is created. As illustrated in FIG. 1, the mat includes both longitudinal bars and transverse bars.

[0031] Two mats are then placed into a cage welder 20, in which C-shaped connector bars or H-clips are utilized to secure the mats together to create a metal cage 22. The H-clips (or C-shaped connectors) secure the mats together in a parallel manner so that the mats are separated throughout the cage by the distance defined by the H-clip (or C-shaped connector). FIG. 2 shows a perspective view of a reinforcement cage 60 located within a concrete panel 61, in accordance with one aspect of the prior art. The metal cage 61 includes an upper mat 66 connected to a lower mat 67 by a plurality of C-shaped connectors 65. The upper mat 66 and lower mat 67 include a plurality of longitudinal bars 68 and transverse bars 64 that make up the mats.

[0032] Referring again to the process 1 illustrated in FIG. 1, after the metal cage is created 22, the cage is subjected to an anti-corrosion process 24, in which the cage is dipped or sprayed with an anti-corrosion agent, as is well known in the art. The cage is also dipped into a coating material, such as a vinyl material, to protect the cage. The primary purpose of the anti-corrosion agent and dipping process is to prevent corrosion of the cage (e.g., rusting), which can have a negative impact on the strength of the reinforced concrete panel. The cage is then dried 26 and hung 28 on a bridge 33 by one or more of the H-clips (or C-shaped connectors). Typically, as illustrated at step 32 of FIG. 1, the bridge 33 supports a plurality of cages, each constructed as described above. The bridge 33 is then lowered into the mold so that multiple metal cages hanging therefrom are placed within the mold 35. Therefore, the function of the bridge 33 is to support the cages while the cement mix (or slurry) is added to the mold 35. According to one aspect of the present invention, the cement mix can include finely ground components of sand, lime, cement, a sulfate component, water and aluminum powder or another reactive agent to produce aerated autoclaved concrete.

[0033] After the slurry rises 34 to fill the mold 35, the bridge is raised 36, leaving the cages within the cake (i.e., the slurry which is now less viscous). The mold, with the cake therein, is then rotated 90 degrees 38, so that the cake is on its side and the cages lay flat 40, as is illustrated in FIG. 1. The cake may then be cut in between the cages so that smaller individual concrete panels are formed. Because the cake has not yet fully hardened, and remains wet, this cutting is accomplished by wires. After smaller individual concrete panels are cut, the concrete panels are inserted into an autoclave for curing 42. Once curing is completed, the panels may be separated as needed for specialized cuts 44, which now must be accomplished by saws in a dry cut process 46. Thereafter, the reinforced concrete panels are complete 48.

[0034] Although the structure illustrated above with respect to FIGS. 1 and 2 is acceptable for producing reinforced concrete structures, the presence of both longitudinally extending rods and transverse rods increases the expense of the reinforcing cage and the concrete panels due to the amount of cutting, reinforcing and welding of the rods that is required to produce the reinforcing cage. Additionally, the primary purpose of the transverse rods, to stabilize the longitudinal rods, its compromised where the end of a panel must be cut off (i.e., where a concrete panel is cut in the transverse direction), because the transverse rods may be cut out of the structure. As a result, care must be taken to ensure that an adequate number of transverse anchor bars remain after dry-cutting to meet the tensile anchorage requirements of the longitudinal reinforcement. The present invention overcomes these problems of the prior art.

[0035]FIG. 3 shows a section of a spiral metal bar 70 for use in reinforcing concrete panels, according to one aspect of the present invention. According to the present invention a plurality of such bars can be used to replace the metal cage for reinforcing concrete panels. As shown in FIG. 3, the bar 70 includes a circular central portion 72 and a thread portion 74 extending radially outward from the central portion 72. When placed longitudinally in a concrete panel, it will be appreciated that the thread portion 74 of the spiral metal bar 70 helps the bar develop appreciable bond stress within the concrete panel along the bar's length, which appropriately strengthens the concrete panel. Therefore, the spiral metal bar achieves the function performed by both the transverse and longitudinal bars in the conventional example described above. Because the spiral bar is not smooth, like the longitudinal bars described above, it need not rely on transverse bars to strengthen the concrete panel. As a result, a plurality of these spiral bars can be used to create a reinforced concrete structure that is much more simple in design and cost effective.

[0036]FIG. 4A shows a perspective view of a concrete panel 81 having spiral metal bars 83 therein, according to one aspect of the present invention. Additionally, FIG. 4B shows a cross section 85 of the concrete panel 81, including the orientation of the spiral metal bars 83 therein, according to one aspect of the present invention. As can be seen in the figures, the reinforced concrete panel 81 constructed using spiral metal bars (or spiral reinforcing bars) 83 requires no mat, cage or transversal bars. Rather, the panel 81 simply requires the bars 83 to be oriented in a parallel relationship, along a longitudinal axis of the panel 81. Therefore, all spiral bars 83 are oriented perpendicular to the transverse axis of the panel 81. Nevertheless, the concrete panel illustrated in FIGS. 4A and 4B is comparable to the panel shown in FIG. 2 because the threads 74 within the spiral bars 83 help the bars 83 develop bonds between each bar and the adjacent concrete. Furthermore, because the spiral bars 83 adhere to adjacent concrete along the entire length of each bar 83, and because no transverse bars are needed to facilitate adhesion between concrete and bars oriented longitudinally within the panel, the concrete panel may be cut along a transverse axis without compromising the integrity of the reinforcement, unlike in the prior art.

[0037] Although the concrete panel illustrated in FIG. 4A and 4B is illustrated as having six (6) spiral metal bars located therein, it will be appreciated by those of ordinary skill in the art that any number of metal bars may be utilized as needed to achieve a concrete panel of particular strength. Furthermore, the thickness of the spiral bars may vary depending upon the strength required of the concrete panel. According to one embodiment of the invention, the spiral bars range in thickness between 5 mm and 15 mm, with a preferred thickness of 10 mm.

[0038] It should also be appreciated by those of skill in the art that the advantages achieved by the spiral metal bar 70 may also be achieved using reinforcement bars of different shapes. For instance, shaped reinforcement bars that are generally circular but have ridges therein or nodes or other protrusions thereon may be used in place of the spiral metal bars 70 to implement the present invention. According to one aspect of the invention, a shaped reinforcement bar used to reinforce concrete panels can include spikes or protuberances extending from a central portion that is circular, square, rectangular or multi-faceted. For example, a shaped reinforcement bar having a cross sectional geometry that is star-shaped might be utilized in the present invention. Thus, virtually any shaped reinforcement bar can be utilized to reinforce concrete without the need for transverse bars, so long as the shape provides enough adhesion between the bar and the adjacent concrete, and the bar can withstand the pressure along its longitudinal axis required for the concrete panel in which it is implemented.

[0039]FIG. 5 shows a hanger assembly 72 for inserting spiral metal bars 70 into concrete, according to one aspect of the present invention. The hanger assembly 72 is suspended from the bridge by a needle 74, which comprises a relatively long and straight rod and handle 76. The hanger assembly 72 releasably secures in a parallel orientation a plurality of the spiral metal bars 70 on each side of the assembly 72. The assembly 72 secures the bars 70 to the assembly through the use of a clip or snap clip 78. To place the bars 70 within a concrete panel, the assembly 72 is lowered into the mold by the bridge 33, as in step 30 in FIG. 1, and remains in the mold until the viscosity of the concrete mix within the mold is sufficient to retain the position and orientation of the spiral metal bars 70 placed therein. After this occurs the hanger assembly 72 releases the bars 70 from the assembly 72, and is removed from the concrete mix. The hanger assembly may release the bars 70 via actuation of the clips 78, either mechanically or electronically or a combination thereof, or may apply pressure, such as a downward force, to cause the bars, which are encased in the slurry or concrete mix, to release from the snap clips 78. Because the assembly 72 is at least the width between adjacent bars 70, removing the assembly 72 from the concrete mix without disturbing the orientation of the bars 70 may require that the assembly be rotated by the needle 74 with the aid of the handle 76. For instance, in the embodiment shown in FIG. 5, where the assembly is relatively wide but shallow in depth, the assembly may be rotated 90 degrees to facilitate its removal.

[0040] According to one preferred embodiment of the present invention, spiral metal bars or the like may be constructed out of stainless steel. The use of stainless steel eliminates the need for corrosion protection, dipping 24, and drying 26, illustrated in FIG. 1. However, any number of materials may be used, including steel, aluminum, carbon, steel alloy, aluminum alloy, and a steel alloy. Furthermore, according to another advantageous embodiment, the spiral metal bars may be purchased or obtained in sections that do not require straightening and/or cutting. Where this occurs, it will be appreciates that steps 10-26 in FIG. 1 are eliminated by the present invention, resulting in a significant reduction in the cost of fabricating the reinforced concrete.

[0041] Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. 

That which is claimed is:
 1. A reinforced concrete panel, wherein said reinforced concrete panel comprises at least one spiral metal bar therein for reinforcing said reinforced concrete panel.
 2. The reinforced concrete panel of claim 1, wherein said reinforced concrete panel is an autoclaved aerated concrete panel.
 3. The reinforced concrete panel of claim 1, wherein said at least one spiral metal bar is constructed of a metal selected from the group consisting of steel, aluminum, carbon, steel alloy, aluminum alloy, stainless steel, and a steel alloy.
 4. The reinforced concrete panel of claim 1, wherein said reinforced concrete panel comprises a longitudinal axis and a transverse axis, and wherein said at least one spiral metal bar is oriented lengthwise in the direction of the longitudinal axis.
 5. The reinforced concrete panel of claim 1, wherein said at least one spiral metal bar comprises a plurality of spiral metal bars, and wherein each one of said plurality of spiral metal bars is parallel to each other one of said plurality of spiral metal bars.
 6. The reinforced concrete panel of claim 1, wherein said reinforced concrete panel comprises a longitudinal axis and a transverse axis, wherein the longitudinal axis defines the length of the concrete panel, and wherein the at least one spiral metal bar runs substantially the entire length of the reinforced concrete panel.
 7. The reinforced concrete panel of claim 1, wherein the at least one spiral metal bar comprises a protective coating thereon.
 8. A method for constructing a reinforced concrete panel using at least one spiral metal bar, comprising: inserting the at least one spiral metal bar into a mold that is to receive a concrete mix; pouring a concrete mix into the mold, wherein said mold defines the shape of the concrete mix during a reduction of the viscosity of the concrete mix, and removing said mold, after said concrete mix can retain the shape of the mold without the mold, to produce a reinforced concrete panel.
 9. The method of claim 8, wherein inserting the at least one spiral metal bar into a mold comprises inserting a plurality of spiral metal bars into said mold, wherein each one of said plurality of spiral metal bars is parallel to each other one of said plurality of spiral metal bars.
 10. The method of claim 8, further comprising cutting said reinforced concrete panel after the reinforced concrete panel has been removed from said mold, to produce a plurality of small reinforced concrete panels.
 11. The method of claim 8, further comprising curing said reinforced concrete panel.
 12. The method of claim 8, wherein inserting the at least one spiral metal bar into said mold comprises: releasably mounting the at least one spiral metal bar to a hanger assembly, and lowering said hanger assembly into said mold.
 13. The method of claim 8, further comprising releasing the at least one spiral metal bar from said hanger assembly after pouring the concrete mix into the mold and prior to removing said mold.
 14. The method of claim 13, wherein releasing the at least one spiral metal bar from said hanger assembly comprises rotating said hanger assembly to release the at least one spiral metal bar.
 15. A system for constructing reinforced concrete panels, comprising: a mold for receiving concrete mix, and for maintaining the shape of said concrete mix during the reduction in viscosity of said concrete mix, and a hanger assembly for releasably securing in a parallel orientation a plurality of spiral metal bars, wherein said hanger assembly is lowered into said mold, and wherein said hanger assembly is removed from said concrete mix after releasing said plurality of spiral metal bars into said concrete mix after the viscosity of said concrete mix is sufficient to retain the position of said spiral metal bars in said concrete mix.
 16. The system of claim 15, further comprising a bridge located substantially above the mold, and wherein the hanger assembly is supported by said bridge.
 17. The system of claim 16, further comprising a needle connecting the hanger assembly and the bridge, wherein the needle is rotatable with respect to the bridge to facilitate the release of the plurality of spiral metal bars from said hanger assembly.
 18. The system of claim 15, wherein said hanger assembly comprises a plurality of clips for releasably securing said plurality of spiral metal bars to said hanger assembly.
 19. A reinforced concrete panel, wherein said reinforced concrete panel comprises at least one shaped reinforcement bar therein for reinforcing said reinforced concrete panel.
 20. The reinforced concrete panel of claim 19, wherein said reinforced concrete panel is an autoclaved aerated concrete panel.
 21. The reinforced concrete panel of claim 19, wherein said at least one shaped reinforcement bar is constructed of a metal selected from the group consisting of steel, aluminum, carbon, steel alloy, aluminum alloy, stainless steel, and a steel alloy.
 22. The reinforced concrete panel of claim 19, wherein said reinforced concrete panel comprises a longitudinal axis and a transverse axis, and wherein said at least one shaped reinforcement bar is oriented lengthwise in the direction of the longitudinal axis.
 23. The reinforced concrete panel of claim 19, wherein said at least one shaped reinforcement bar comprises a plurality of shaped reinforcement bars, and wherein each one of said plurality of shaped reinforcement bars is parallel to each other one of said plurality of shaped reinforcement bars.
 24. The reinforced concrete panel of claim 19, wherein said reinforced concrete panel comprises a longitudinal axis and a transverse axis, wherein the longitudinal axis defines the length of the concrete panel, and wherein the at least one shaped reinforcement bar runs substantially the entire length of the reinforced concrete panel. 